Refrigerator appliance and a door for an appliance

ABSTRACT

A door for an appliance is provided. The door of the appliance includes an outer panel with a rear surface. The door also includes a vacuum insulation panel and a barrier layer. The barrier layer is positioned between the rear surface of the outer panel and the vacuum insulation panel within the door.

FIELD OF THE INVENTION

The present subject matter relates generally to appliances, such as refrigerator appliances, and doors for the same.

BACKGROUND OF THE INVENTION

Vacuum insulation panels generally include a nearly gas-tight enclosure surrounding a rigid core, from which atmospheric gases have been at least partially evacuated. Certain refrigerator appliances include vacuum insulation panels for thermally insulating a cabinet and/or doors of the refrigerator appliances. The vacuum insulation panels can decrease heat leakage into chilled chambers of the refrigerator appliances and thereby increase an efficiency of the refrigerator appliance. To further increase the efficiency of the refrigerator appliance, the vacuum insulation panels can be utilized in combination with conventional foam or fiberglass insulation within the cabinet and doors of the refrigerator appliances. In certain refrigerator appliances, the vacuum insulation panels are attached or mounted directly to metal outer panels of the cabinet and/or doors prior to inserting the additional insulating material.

Vacuum insulation panels mounted directly to metal panels of a refrigerator appliance's cabinet and/or doors have several drawbacks. For example, edge effects can decrease a thermal efficiency of the vacuum insulation panel. In addition, a shape of the vacuum insulation panel can transfer or be impressed on the outer panel such that a cosmetic appearance of the outer panel is negatively affected. In particular, the outer panel can appear unsmooth. Further, suitable adhesion between the vacuum insulation panel and the outer panel can be difficult if a surface finish of the vacuum insulation panel is not sufficiently smooth and includes irregularities. Thus, a cost of the vacuum insulation panel may be increased due to the tolerances required to properly adhere the vacuum insulation panel directly to the metal outer panel. In particular, expensive bonding methods and/or adhesives may be required to properly attach the vacuum insulation panel directly to the metal outer panel.

Accordingly, a door for an appliance with features for assisting with mounting a vacuum insulation panel within the door would be useful. In particular, a door for an appliance with features for bolstering a thermal efficiency of a vacuum insulation panel within the door would be useful. In addition, a door for an appliance with a vacuum insulation panel within the door and features for providing an outer panel with a smooth outer surface would be useful. Further, a door for an appliance with features for assisting with suitably mounting a vacuum insulation panel within the door would be useful.

BRIEF DESCRIPTION OF THE INVENTION

The present subject matter provides a refrigerator appliance with a door. The door includes an outer panel with a rear surface, a vacuum insulation panel and a barrier layer. The barrier layer is positioned between the rear surface of the outer panel and the vacuum insulation panel within the door. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In a first exemplary embodiment, a refrigerator appliance is provided. The refrigerator appliance includes a cabinet that defines a chilled chamber. A door is positioned adjacent the cabinet when the door is in a closed position. The door includes an outer panel that has a front surface and a rear surface positioned opposite each other on the outer panel. The door also includes a vacuum insulation panel and a barrier layer. The barrier layer is positioned between the rear surface of the outer panel and the vacuum insulation panel within the door.

In a second exemplary embodiment, a door for an appliance is provided. The door includes an outer panel with a front surface and a rear surface positioned opposite each other on the outer panel. An inner liner is mounted to the outer panel. The outer panel and the inner liner define an interior volume therebetween. A vacuum insulation panel is positioned within the interior volume. A barrier layer is positioned between the rear surface of the outer panel and the vacuum insulation panel.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a front, elevation view of a refrigerator appliance according to an exemplary embodiment of the present subject matter.

FIG. 2 provides a front, elevation view of the exemplary refrigerator appliance of FIG. 1. In FIG. 2, refrigerator doors of the exemplary refrigerator appliance are shown in an open position in order to reveal a fresh food chamber of the exemplary refrigerator appliance.

FIG. 3 provides a rear, perspective view of certain components of a door assembly according to an exemplary embodiment of the present subject matter.

FIG. 4 provides an exploded view of the certain components of the exemplary door assembly of FIG. 3.

FIG. 5 provides a section view of the certain components of the exemplary door assembly of FIG. 3 taken along the 5-5 line of FIG. 3.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 provides a front, elevation view of a refrigerator appliance 100 according to an exemplary embodiment of the present subject matter with refrigerator doors 128 of the refrigerator appliance 100 shown in a closed position. FIG. 2 provides a front view of refrigerator appliance 100 with refrigerator doors 128 shown in an open position to reveal a fresh food chamber 122 of refrigerator appliance 100.

Refrigerator appliance 100 includes a cabinet or housing 120 that extends between a top 101 and a bottom 102 along a vertical direction V. Housing 120 defines chilled chambers for receipt of food items for storage. In particular, housing 120 defines fresh food chamber 122 positioned at or adjacent top 101 of housing 120 and a freezer chamber 124 arranged at or adjacent bottom 102 of housing 120. As such, refrigerator appliance 100 is generally referred to as a bottom mount refrigerator. It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance or a side-by-side style refrigerator appliance. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular refrigerator chamber configuration.

Refrigerator doors 128 are rotatably hinged to an edge of housing 120 for selectively accessing fresh food chamber 122. In addition, a freezer door 130 is arranged below refrigerator doors 128 for selectively accessing freezer chamber 124. Freezer door 130 is coupled to a freezer drawer (not shown) slidably mounted within freezer chamber 124. As discussed above, refrigerator doors 128 and freezer door 130 are shown in the closed configuration in FIG. 1, and refrigerator doors 128 are shown in the open position in FIG. 2.

Turning now to FIG. 2, various storage components are mounted within fresh food chamber 122 to facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components include bins 140, drawers 142, and shelves 144 that are mounted within fresh food chamber 122. Bins 140, drawers 142, and shelves 144 are configured for receipt of food items (e.g., beverages and/or solid food items) and may assist with organizing such food items. As an example, drawers 142 can receive fresh food items (e.g., vegetables, fruits, and/or cheeses) and increase the useful life of such fresh food items.

As also may be seen in FIG. 2, refrigerator doors 128 include outer panels 132 and inner liners 134. Each refrigerator door of refrigerator doors 128 includes a respective one of outer panels 132 and inner liners 134 mounted to each other. Insulation, such as sprayed polyurethane foam, may be disposed between outer panels 132 and inner liners 134 within refrigerator doors 128 in order to assist with insulating fresh food chamber 122 when refrigerator doors 128 are in the closed position. Outer panels 132 and inner liners 134 may be constructed of or with any suitable materials. For example, outer panels 132 may be constructed of or with a metal, such a stainless steel or painted steel, and inner liners 134 may be constructed of or with a suitable plastic material. Freezer door 130 may be constructed in a similar manner as refrigerator doors 128.

FIG. 3 provides a rear, perspective view of a door assembly 200 according to an exemplary embodiment of the present subject matter. FIG. 4 provides an exploded view of door assembly 200, and FIG. 5 provides a section view of door assembly 200 taken along the 5-5 line of FIG. 3. Door assembly 200 may be used in any suitable appliance. For example, door assembly 200 may be used in refrigerator appliance 100 as refrigerator doors 128 and/or freezer door 130. Door assembly 200 includes features for improving performance of a vacuum insulation panel 220 of door assembly 200 as well as an appearance of an outer panel 210 of door assembly 200.

Door assembly 200 defines a vertical direction V, a lateral direction L and a transverse direction T. The vertical direction V, the lateral direction L and the transverse direction T are mutually perpendicular and form an orthogonal direction system. Outer panel 210 of door assembly 200 has a front surface 212 and a rear surface 214. Front and rear surfaces 212 and 214 of outer panel 210 are positioned opposite each other on outer panel 210, e.g., such that front and rear surfaces 212 and 214 of outer panel 210 are spaced apart from each other along the transverse direction T. Front surface 212 of door assembly 200 may be exposed such that front surface 212 of door assembly 200 is visible to a user of an associated appliance. Conversely, rear surface 214 of door assembly 200 may face an interior volume 216 of door assembly 200. The interior volume 216 of door assembly 200 may be defined between outer panel 210 and an inner liner (not shown) that is mounted to outer panel 210.

Vacuum insulation panel 220 is positioned or disposed within door assembly 200, e.g., within interior volume 216 of door assembly 200. Vacuum panel 220 assists with limiting heat transfer as will be understood by those skilled in the art. To facilitate the insulation of an associated appliance, a shape of vacuum insulation panel 220 may be substantially similar to or complementary to a shape of outer panel 210, e.g., in a plane that is perpendicular to the transverse direction T.

Vacuum insulation panel 220 may be constructed in any suitable manner. For example, vacuum insulation panel 220 may include an outer conductive film 222 that defines an interior vacuum chamber (not shown) of vacuum insulation panel 220. The interior vacuum chamber of vacuum insulation panel 220 may be filled with an insulating media (not shown), such as fiberglass, foamed insulation, etc. The interior vacuum chamber of vacuum insulation panel 220 may be at least partially evacuated of atmospheric gases to form vacuum insulation panel 220. The insulating media within the interior vacuum chamber of vacuum insulation panel 220 may oppose atmospheric pressure that urges vacuum insulation panel 220 to collapse. The outer conductive film 222 may be constructed of or with any suitable material. For example, outer conductive film 222 may be constructed of or with aluminum.

Door assembly 200 also includes a barrier pad or layer 230. Barrier layer 230 is positioned between outer panel 210 and vacuum insulation panel 220, e.g., along the transverse direction T, within interior volume 216 of door assembly 200. In the exemplary embodiment shown in FIG. 5, barrier layer 230 is positioned on outer panel 210, e.g., at rear surface 214 of outer panel 210. In particular, barrier layer 230 may be adhered to outer conductive film 222 of vacuum insulation panel 220 and rear surface 214 of outer panel 210 such that barrier layer 230 extends between outer conductive film 222 of vacuum insulation panel 220 and rear surface 214 of outer panel 210, e.g., along the transverse direction T, within interior volume 216 of door assembly 200. An adhesive, such as a pressure sensitive adhesive or an acrylic adhesive, may be applied to both side of barrier layer 230 to assist with adhering barrier layer 230 to vacuum insulation panel 220 and outer panel 210. Clips 228 may also assist with coupling vacuum insulation panel 220 to outer panel 210. In particular, clips 228 may be mounted to outer panel 210 and hinder movement of vacuum insulation panel 220 relative to outer panel 210, e.g., along the transverse direction T. However, it should be understood that barrier layer 230 may be mounted within interior volume 216 of door assembly 200 using any suitable method or mechanism in alternative exemplary embodiments.

A shape of barrier layer 230 may be complementary to the shape of vacuum insulation panel 220. For example, the shape of barrier layer 230 may be substantially rectangular, e.g., in a plane that is perpendicular to the transverse direction T, and the shape of vacuum insulation panel 220 may also be substantially rectangular, e.g., in the plane that is perpendicular to the transverse direction T. A size of barrier layer 230 may be substantially similar to a size of vacuum insulation panel 220, e.g., in the plane that is perpendicular to the transverse direction T.

Barrier layer 230 can assist with improving a thermal efficiency of vacuum insulation panel 220, e.g., by acting as a thermal break between outer panel 210 and vacuum insulation panel 220. In particular, barrier layer 230 may reduce or eliminate conductive heat transfer between the outer conductive film 222 of vacuum insulation panel 220 and outer panel 210, e.g., that is also constructed of a conductive material, such as steel. Further, barrier layer 230 can assist with reducing edge effects of heat transfer through vacuum insulation panel 220 by spacing the outer conductive film 222 of vacuum insulation panel 220 from outer panel 210. Reduced conductive heat transfer and edge effects can also assist with reducing sweat on outer panel 210, e.g., in high humidity conditions. In such a manner, a cosmetic appearance of door assembly 200, e.g., in high humidity conditions, can be improved.

Barrier layer 230 can also improve the cosmetic appearance of outer panel 210 by limiting or preventing a shape of vacuum insulation panel 220 from transferring and appearing on outer panel 210. In particular, if an outer surface of vacuum insulation panel 220 is not smooth and vacuum insulation panel 220 is mounted directly to outer panel 210, the variations in vacuum insulation panel 220 can transfer to outer panel 210 and make outer panel 210 appear unsmooth. Barrier layer 230 can be sufficiently flexible to limit or avoid such transfer. In such a manner, tolerance in the shape of vacuum insulation panel 220 can be increased. In addition, barrier layer 230 can improve a dent resistance of outer panel 210 by providing space for outer panel 210 to deflect during impacts.

Barrier layer 230 may be constructed of or with any suitable material. In particular, barrier layer 230 may be constructed of or with a substantially flexible material having a suitably low thermal conductivity such that barrier layer 230 may act as a flexible thermal break between outer panel 210 and vacuum insulation panel 220. As an example, barrier layer 230 may be constructed of or with a plastic foam, such as low density polyethylene or polypropylene foam, or a low density fiber material (e.g., a high loft, low density nonwoven material), such as a cotton fiber material or cotton shoddy (e.g., regenerated cotton pulp fibers). As another example, barrier layer 230 may be constructed of or with a material conforming to A5OLE100,TSL3505G-6 or an engineering equivalent.

A thickness, t, of barrier layer 230, e.g., along the transverse direction T, may be any suitable thickness. For example, the thickness t of barrier layer 230 may be (e.g., less than) about one quarter of an inch, e.g., along the transverse direction T. Thus, with barrier layer 230 positioned between outer panel 210 and vacuum insulation panel 220, the outer conductive film 222 of vacuum insulation panel 220 may be spaced apart from o the rear surface 214 of outer panel 210, e.g., along the transverse direction T, by (e.g., less than) about one quarter of an inch. As another example, the thickness t of barrier layer 230 may be (e.g., less than) about one eighth of an inch, e.g., along the transverse direction T. As yet another example, the thickness t of barrier layer 230 may be (e.g., less than) about one half of an inch, e.g., along the transverse direction T.

A density of barrier layer 230 may be any suitable density. For example, the density of barrier layer 230 may be less than about four hundredths of a gram per centimeter cubed. As another example, the density of barrier layer 230 may be less than about one tenth of a gram per centimeter cubed. In addition, a thermal conductivity of barrier layer 230 may be any suitable thermal conductivity. For example, the thermal conductivity of barrier layer 230 may be less than about one third of a watt per meter kelvin. As another example, the thermal conductivity of barrier layer 230 may be less than about one watt per meter kelvin.

To further assist with insulating door assembly 200, an insulating foam (not shown), such as a polyurethane foam, may be positioned or disposed within interior volume 216 of door assembly 200. The insulating foam and barrier layer 230 may be positioned opposite each other on vacuum insulation panel 220. In particular, vacuum insulation panel 220 may be positioned between the insulating foam and barrier layer 230 within interior volume 216 of door assembly 200. For example, vacuum insulation panel 220 may extend between a first side portion 224 and a second side portion 226, e.g., along the transverse direction T. Barrier layer 230 may be positioned on or at first side portion 224 of vacuum insulation panel 220, and the insulating foam may be positioned on or at second side portion 226 of vacuum insulation panel 220.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A refrigerator appliance, comprising: a cabinet defining a chilled chamber; a door positioned adjacent the cabinet when the door is in a closed position, the door comprising an outer panel having a front surface and a rear surface positioned opposite each other on the outer panel; a vacuum insulation panel; a barrier layer positioned between the rear surface of the outer panel and the vacuum insulation panel within the door.
 2. The refrigerator appliance of claim 1, wherein a shape of the barrier layer is complementary to a shape of the vacuum insulation panel.
 3. The refrigerator appliance of claim 2, wherein the shape of the barrier layer is substantially rectangular and the shape of the vacuum insulation panel is substantially rectangular.
 4. The refrigerator appliance of claim 1, wherein the vacuum insulation panel comprises an outer conductive film, the barrier layer positioned on the outer conductive film of the vacuum insulation panel and the rear surface of the outer panel such that the barrier layer extends between the outer conductive film of the vacuum insulation panel and the rear surface of the outer panel.
 5. The refrigerator appliance of claim 1, wherein the barrier layer comprises a plastic foam or a low density fiber material.
 6. The refrigerator appliance of claim 1, wherein a thickness of the barrier layer is less than about one half of an inch.
 7. The refrigerator appliance of claim 6, wherein a density of the barrier layer is less than about one tenth of a gram per centimeter cubed.
 8. The refrigerator appliance of claim 6, wherein a thermal conductivity of the barrier layer is less than about one watt per meter kelvin.
 9. The refrigerator appliance of claim 1, wherein further comprising an insulating foam positioned within the door, the insulating foam and the barrier layer positioned opposite each other on the vacuum insulation panel.
 10. The refrigerator appliance of claim 8, wherein the vacuum insulation panel is positioned between the insulating foam and the barrier layer within the door.
 11. The refrigerator appliance of claim 1, wherein the outer panel comprises steel.
 12. A door for an appliance, comprising: an outer panel having a front surface and a rear surface positioned opposite each other on the outer panel; an inner liner mounted to the outer panel, the outer panel and the inner liner defining an interior volume therebetween; a vacuum insulation panel positioned within the interior volume; and a barrier layer positioned between the rear surface of the outer panel and the vacuum insulation panel.
 13. The door of claim 12, wherein a shape of the barrier layer is substantially rectangular and a shape of the vacuum insulation panel is substantially rectangular.
 14. The door of claim 12, wherein the vacuum insulation panel comprises an outer conductive film, the barrier layer positioned on the outer conductive film of the vacuum insulation panel and the rear surface of the outer panel such that the barrier layer extends between the outer conductive film of the vacuum insulation panel and the rear surface of the outer panel.
 15. The door of claim 12, wherein the barrier layer comprises a plastic foam or a low density fiber material.
 16. The door of claim 12, wherein a thickness of the barrier layer is less than about one half of an inch.
 17. The door of claim 16, wherein a density of the barrier layer is less than about one tenth of a gram per centimeter cubed.
 18. The door of claim 16, wherein a thermal conductivity of the barrier layer is less than about one watt per meter kelvin.
 19. The door of claim 12, wherein further comprising an insulating foam positioned within the interior volume, the vacuum insulation panel positioned between the insulating foam and the barrier layer within the interior volume.
 20. The door of claim 12, wherein the outer panel comprises steel. 